Electronic package structure and method for manufacturing the same

ABSTRACT

An electronic package structure and a method for manufacturing the same are provided. The electronic package structure includes a first electronic component, a second electronic component, an interconnection element, an insulation layer, and an encapsulant. The second electronic component is disposed adjacent to the first electronic component. The interconnection element is disposed between the first electronic component and the second electronic component. The insulation layer is disposed between the first electronic component and the second electronic component and has a side surface and a top surface connecting to the side surface. The encapsulant surrounds the interconnection element and at least partially covers the top surface of the insulation layer and has an extended portion in contact with the side surface of the insulation layer.

BACKGROUND 1. Technical Field

The present disclosure relates generally to electronic package structures and methods for manufacturing the same.

2. Description of the Related Art

Undesired warpage of an electronic component may occur due to a CTE (coefficient of thermal expansion) mismatch between a substrate or a printed circuit board and the electronic component bonded thereon. The warpage may cause the distance between a surface of the electronic component and a surface of the substrate to vary from edge to center. For example, a distance between an edge of a surface of the electronic component and a surface of the substrate may be greater than that between a center of the surface of the electronic component and the surface of the substrate. As such, the conductive layers on the edge of the surface of the electronic component may not be able to successfully bond to the corresponding conductive layers on the substrate as they are spaced farther apart, which may affect performance and reliability of the electronic component. For these and other reasons, various electronic package structures and methods for manufacturing the same are being developed.

SUMMARY

In some arrangements, an electronic package structure includes a first electronic component, a second electronic component, an interconnection element, an insulation layer, and an encapsulant. The second electronic component is disposed adjacent to the first electronic component. The interconnection element is disposed between the first electronic component and the second electronic component. The insulation layer is disposed between the first electronic component and the second electronic component and has a side surface and a top surface connecting to the side surface. The encapsulant surrounds the interconnection element and at least partially covers the top surface of the insulation layer and has an extended portion in contact with the side surface of the insulation layer.

In some arrangements, a method for manufacturing an electronic package structure includes: providing a first electronic component including a first conductive layer and a second electronic component including a second conductive layer; pressing the first electronic component to partially interconnect the first conductive layer and the second conductive layer; and applying a condensed energy on the first electronic component to completely interconnect the first conductive layer and the second conductive layer.

In some arrangements, an electronic package structure includes an electronic component and an encapsulant. The electronic component is connected to a carrier through a connection structure. The encapsulant accommodates the connection structure and includes an extension between the connection structure and the carrier. The extension is configured to hinder delamination between the encapsulant and an upper surface of the carrier.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a cross-sectional view of an electronic package structure according to some arrangements.

FIG. 2 illustrates a cross-sectional view of an electronic package structure according to some arrangements.

FIG. 3 illustrates a cross-sectional view of an electronic package structure according to some arrangements.

FIG. 4A and FIG. 4B illustrate various operations in a method for manufacturing an electronic package structure according to some arrangements.

DETAILED DESCRIPTION

Spatially relative terms, such as “top,” “bottom,” “beneath,” “below,” “above,” “over,” “on,” “upper,” “lower,” “left,” “right,” “vertical,” “horizontal,” “side” and the like, may be used herein for ease of description of one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly. It should be understood that when an element is referred to as being “connected to” or “coupled to” another element, it may be directly connected or coupled to the other element, or intervening elements may be present.

FIG. 1 illustrates a cross-sectional view of an electronic package structure 100 according to some arrangements of the present disclosure. The electronic package structure 100 of FIG. 1 includes a first electronic component 101, a second electronic component 103, an interconnection element 109, an insulation layer 111, and an encapsulant 115.

The first electronic component 101 may include at least one first pad 106 disposed adjacent to a lower surface 101 a of a main body 102 thereof. The first electronic component 101 may be or include an active component (e.g., a die or a chip). In some examples, the first electronic component 101 may be or include a die. A conductive bump 107 may be disposed adjacent to or on the lower surface 101 a of the main body 102. For example, in some arrangements, the conductive bump 107 may be disposed adjacent to or on the first pad 106 of the main body 102. The conductive bump 107 may electrically connect to the lower surface 101 a of the main body 102 through the first pad 106. In some examples, the conductive bump 107 is disposed on (e.g., physically contacts) the first pad 106.

The conductive bump 107 has a first surface (an upper surface) 107 b facing the first electronic component 101 and a second surface (a lower surface) 107 a opposite to the first surface 107 b. An edge 107 d of the first surface 107 b of the conducive bump 107 may incline toward the first electronic component 101. The edge 107 d of the first surface 107 b of the conductive bump 107 may be closer to the main body 102 than a non-edge portion of the first surface 107 b is. The first surface 107 b may include an inclined surface 107 s. In some examples, the inclined surface 107 s slopes down from the edge 107 d to a center of the first surface 107 b. The first surface 107 b may have a sharp corner at the edge 107 d from a cross-sectional perspective. The second surface 107 a may be an uneven surface. In some arrangements, the second surface 107 a may be or include a curved surface. A recess 107 c may be located at the second surface 107 a. The recess 107 c may be located at or adjacent to a center of the second surface 107 a. A width of the conductive bump 107 may be greater than a width of the first pad 106. The conductive bump 107 may be a pillar or a solder/stud bump.

The second electronic component 103 is disposed adjacent to the first electronic component 101. The second electronic component 103 has an upper surface 103 a facing the second surface 107 a of the conductive bump 107 and the lower surface 101 a of the main body 102. The second electronic component 103 may include a circuit pattern on the upper surface 103 a and/or a circuit pattern embedded therein. A second pad 105 may be disposed adjacent to or on (e.g., physically contact) the upper surface 103 a of the second electronic component 103. The second pad 105 may be a part of the circuit pattern of the second electronic component 103 or may electrically connect to the circuit pattern of the second electronic component 103. The second electronic component 103 may be, for example but not limited to, a carrier, a substrate, a die or a chip, a quad flat no-lead (QFN) package, a dual flat no-lead (DFN) package, a lead frame, a printed circuit board, an interposer, or a redistribution layer. In some examples, the second electronic component 103 is a substrate or a printed circuit board.

The interconnection element 109 is disposed between the first electronic component 101 and the second electronic component 103. The interconnection element 109 may be disposed between the conductive bump 107 and the second pad 105. The interconnection element 109 may electrically connect to the conductive bump 107 and the second pad 105. The interconnection element 109 may bond to the conductive bump 107 and the second pad 105. The interconnection element 109 may be configured to join the conductive bump 107 to the second pad 105. The interconnection element 109 has a first surface (an upper surface) 109 a facing the conductive bump 107. The first surface (an upper surface) 109 a may also face the main body 102 of the first electronic component 101. The first surface 109 a of the interconnection element 109 may be an uneven surface. The first surface 109 a may be or include a curved surface. In some examples where the interconnection element 109 connects to the conductive bump 107 directly, the first surface 109 a (or the second surface 107 a of the conductive bump 107) is also the interface 110 at which the conductive bump 107 and the interconnection element 109 connects. The first surface 109 a of the interconnection element 109 may conform to the shape of the second surface 107 a of the conductive bump 107. In some arrangements, the conductive bump 107 together with the interconnection element 109 may be referred to as “connection structure” or “electrical connection structure.”

The interconnection element 109 may include a base 109 d and a body 109 e connecting to the base 109 d and farther from the second pad 105 than the base 109 d is. The base 109 d may directly contact the second pad 105. A width of the base 109 d may be greater than a width of the body 109 e. The base 109 d may include a skirt portion 109 s. The body 109 e may include a narrow top portion 109 t, a wide middle portion 109 m, and a narrow bottom portion 109 b. The wide middle portion 109 m may connect to the narrow top portion 109 t and the narrow bottom portion 109 b and form a substantially continuous and curved lateral surface 109 c extending from the interface 110 to the base 109 d. The lateral surface 109 c may be considered substantially continuous when no obvious turning points can be observed under a specific microscope magnification. The interconnection element 109 may include, for example, a soldering material. The soldering material may include Au, Cu, Ni, Sn or a combination of two or more thereof, but is not limited thereto. In some arrangements, the soldering material may include AuSn, CuSn, NiSn, or a combination of two or more thereof, but is not limited thereto.

The insulation layer 111 is disposed between the first electronic component 101 and the second electronic component 103. The insulation layer 111 may be disposed adjacent to or on (e.g., physically contact) the upper surface 103 a of the second electronic component 103. The insulation layer 111 has a first surface (an upper surface or a top surface) 111 a facing the first electronic component 101 and a second surface (a lower surface or a bottom surface) 111 b opposite to the first surface 111 a. A side surface 111 d connects to the top surface 111 a and the bottom surface 111 b. The insulation layer 111 may cover at least a portion of the second pad 105. The insulation layer 111 may cover an edge (e.g., a peripheral edge) of the second pad 105. In some examples, the insulation layer 111 covers at least a portion of the second pad 105 and defines a gap 113 with the interconnection element 109. In some arrangements, the interconnection element 109 has a portion (e.g., 109 b and 109 d) embedded in the insulation layer 111 and connected to the second pad 105 and the gap 113 is defined by the insulation layer 111 and the embedded portion of the interconnection element 109. The gap 113 may extend between the first surface 111 a of the insulation layer 111 and the second surface 111 b of the insulation layer 111. In some arrangements, the gap 113 may extend from the first surface 111 a of the insulation layer 111 to underneath the second surface 111 b of the insulation layer 111. In some arrangements, the second surface 111 b may be spaced from the second pad 105 and the base 109 d of the interconnection element 109 by a portion of the gap 113. A portion of the base 109 d may be between the insulation layer 111 and the second pad 105. The insulation layer 111 may include a curved corner 111 c adjacent to the gap 113. In some examples, the corner 111 c may be a rounded corner. The insulation layer 111 may be, for example, a solder mask (the material of which is, for example, polyimide (PI)), or a passivation layer (the material of which is, for example, a metal oxide).

The encapsulant 115 is disposed between the first electronic component 101 and the second electronic component 103. In some examples, the encapsulant 115 is disposed around the interconnection element 109. In some examples, the encapsulant 115 surrounds the interconnection element 109 and at least partially covers the top surface 111 a of the insulation layer 111. In some examples, the encapsulant 115 accommodates the interconnection element 109. In some examples, at least an extended portion 115 c of the encapsulant 115 is in contact with the side surface 111 d of the insulation layer 111. By contacting the extended portion 115 c of the encapsulant 115 with the side surface 111 d of the insulation layer 111, the contact surface areas between the encapsulant 115 and the insulation layer 111 may be increased so the encapsulant 115 may hold on to the insulation layer 111 more tightly, which may improve the adhesion of the insulation layer 111 to the second electronic component 103 and diminish the occurrence of the delamination of the insulation layer 111 from the second electronic component 103.

In some examples, at least an extended portion 115 c of the encapsulant 115 is in the gap 113. In some examples, at least a portion of an extension 115 c of the encapsulant 115 is in the gap 113 and configured to hinder delamination between the encapsulant 115 and the upper surface 103 a of the second electronic component 103 (or the first surface 111 a of the insulation layer 111) as the extension 115 c may provide mold lock effect to the insulation layer 111. In some examples, the extension 115 c may be configured to enhancing the adhesion between the encapsulant 115 and the upper surface 103 a of the second electronic component 103 (or the first surface 111 a of the insulation layer 111). In some examples where the second electronic component 103 is a carrier and the body 109 e of the interconnection element 109 includes a soldering material, the extension 115 c is disposed between the soldering material 109 and the carrier 103 (or the insulation layer 111). The encapsulant 115 may include an epoxy resin, a molding compound (e.g., an epoxy molding compound or other molding compounds), polyimide, a phenolic compound or material, a material with a silicone dispersed therein, or a combination thereof. In some arrangements, the encapsulant 115 may include an underfill material. In some arrangements, the encapsulant 115 may include fillers, the material of which is, for example, silica and/or carbon, for reducing stress on the substrate and warpage of a resulting electronic package.

By providing a gap 113 defined by the interconnection element 109 and the first insulation layer 111 and filling into the gap a portion (i.e., 115 c) of the encapsulant, a mold lock effect may be provided so the encapsulant 115 may not be easily delaminated from the second electronic component 103 (or the first insulation layer 111). Accordingly, the adhesion effect of the encapsulant 115 to the second electronic component 103 (or the first insulation layer 111) may be improved.

In some arrangements, the electronic package structure 100 further includes a second insulation layer 117 adjacent to or disposed on (e.g., physically contact) the lower surface 101 a of the first electronic component 101. The second insulation layer 117 may be disposed between the first electronic component 101 and the conductive bump 107 and between the first electronic component 101 and the encapsulant 115. The second insulation layer 117 may be disposed around a protrusion portion 107 p of the conductive bump 107. The portion 107 e of the conductive bump 107 may protrude beyond a level of the second insulation layer 117. In some examples, a portion 107 e of the conductive bump 107 may protrude against the second insulation layer 117. The second insulation layer 117 may be, for example, a solder mask (the material of which is, for example, polyimide (PI)), or a passivation layer (the material of which is, for example, a metal oxide).

FIG. 2 illustrates a cross-sectional view of an electronic package structure 200 according to some arrangements of the present disclosure. The electronic package structure 200 illustrated in FIG. 2 is similar to that illustrated in FIG. 1 with a difference being that a first conductive layer 119 a and a second conductive layer 119 b is present in the electronic package structure 200. As illustrated in FIG. 2 , the first conductive layer 119 a is disposed on the conductive pump 107 and the second conductive layer 119 b is disposed on the second pad 105. The first conductive layer 119 a may partially contact the second conductive layer 119 b. In some examples, the first conductive layer 119 a may contact the second conductive layer 119 b at one or more portions (e.g., 120 a, 120 b and/or 120 c). In some examples, the first conductive layer 119 a may contact the second conductive layer 119 b at a center portion (e.g., 120 b) of the interface between the first conductive layer 119 a and the second conductive layer 119 b. Since the first conductive layer 119 a does not connect to the second conductive layer 119 b completely, the bonding strength of the connection structure between the first electronic component 101 and the second electronic component 103 may not be as strong as that shown in FIG. 1 . In some examples, the electronic package structure 200 may be formed by pressing the first electronic component 101 to contact at least a portion of the first conductive layer 119 a to at least a portion of the second conductive layer 119 b by a thermal compression bonding process.

FIG. 3 illustrates a cross-sectional view of an electronic package structure 300 according to some arrangements of the present disclosure. The electronic package structure 300 illustrated in FIG. 3 includes a plurality of connection structures illustrated in FIG. 1 . In some examples, a warpage of the first electronic component 101 may occur due to a CTE (coefficient of thermal expansion) mismatch between the first electronic component 101 and the second electronic component 103. As such, a first distance (height) H1 between an edge of a surface of the first electronic component 101 and a surface of the second electronic component 103 may be greater than a second distance (height) H2 between a center of the surface of the first electronic component 101 and the surface of the substrate. The warpage may be alleviated by adopting a thermal compression bonding process. In some arrangements, although slight warpage may still occur after carrying out a thermal compression bonding process, the first electronic component 101 may still successfully connect to the second electronic component 103 through the plurality of the connection structures illustrated in FIG. 1 .

FIGS. 4A-4B illustrate various operations in a method for manufacturing an electronic package structure such as the electronic package structure of FIG. 1 .

Referring to FIG. 4A, a first electronic component 101 and a second electronic component 103 103 are provided. In some examples, the first electronic component 101 is a die and the second electronic component 103 is a substrate. The first electronic component 101 may include a first conductive layer 119 a disposed on a conductive bump 107 of the first electronic component 101. The second electronic component 103 may include a second conductive layer 119 b disposed on a second pad 105 of the second electronic component 103. The first conductive layer 119 a may be partially interconnected to the second conductive layer 119 b by pressing the first electronic component 101 against the second electronic component 103 (or pressing the second electronic component 103 against the first electronic component 101) via a thermal compression bonding process. In some examples, the thermal compression bonding process is carried out to form a contact between at least a portion of the first conductive layer 119 a and at least a portion of the second conductive layer 119 b, which may partially joint the first conductive layer 119 a to the second conductive layer 119 b. An edge 107 d of a top surface 107 b of the conductive bump 107 may incline toward the first electronic component 101, a recess 107 c may occur at a bottom surface 107 a of the conductive bump 107 by the first conductive layer 119 a, and an uneven surface 119 c of the first conductive layer 119 a facing the first electronic component 101 may be formed because of the pressure applied during the thermal compression bonding process. Afterwards, an electronic package structure (e.g., an electronic package structure 200 as is illustrated in of FIG. 2 ) may be obtained.

By pressing the first electronic component 101 and/or the second electronic component 103 under a pressure prior to applying a condensed energy on the first electronic component 101 to fully joint the first conductive layer 119 a to the second conductive layer 119 b, the extent of the warpage of the first electronic component 101 may be reduced, so that the height difference between the first height H1 between an edge of a surface of the first electronic component 101 and a surface of the second electronic component 103 and the second height H2 between a center of the surface of the first electronic component 101 and the surface of the second electronic component 103 may be decreased. Accordingly, the connection between the first conductive layer 119 a and the second conductive layer 119 b may be improved as they will not be parted far by the warpage.

Referring to FIG. 4B, the first conductive layer 119 a may be completely interconnected to the second conductive layer 119 b and form a joint structure after application of a condensed energy (such as laser energy) on the first electronic component 101. The condensed energy may be supplied by carrying out for example, a laser assisted bonding process, but is not limited thereto). The first conductive layer 119 a connects to the second conductive layer 119 b at an uneven interface 110. In some examples, the first metal layer 119 a may completely joint to the second metal layer 119 b at this stage. Afterwards, an electronic package structure (e.g., an electronic package structure 100 as is illustrated in of FIG. 1 ) may be obtained. Since a pressure is applied to the first electronic component 101 and/or the second electronic component 103 to partially joint the first conductive layer 119 a to the second conductive layer 119 b prior to applying the condensed energy, the first conductive layer 119 a may form a complete joint structure with the second conductive layer 119 b more easily when the condensed energy is applied afterwards. In some examples, a gap 113 is formed between the connection structure (including the conductive bump 107 and the interconnection element 109) and the first insulation layer 111 on the second electronic component 103 because the second conductive layer 119 b may shrink or condense due to the condensed energy. A filling material is filled around the connection structure to form an encapsulant 115. A portion (i.e., 115 c) of the encapsulant 115 may be filled into the gap 113. As a result, a mold lock effect may be provided so the encapsulant 115 may not be easily delaminated from the second electronic component 103 (or the first insulation layer 111). Accordingly, the adhesion effect of the encapsulant 115 to the second electronic component 103 (or the first insulation layer 111) may be improved, which may further improve the strength of the connection structure between the first electronic component 101 and the second electronic component 103.

As used herein and not otherwise defined, the terms “substantially” and “about” are used to describe and account for small variations. When used in conjunction with an event or circumstance, the terms can encompass instances in which the event or circumstance occurs precisely as well as instances in which the event or circumstance occurs to a close approximation. For example, when used in conjunction with a numerical value, the terms can encompass a range of variation of less than or equal to ±10% of that numerical value, such as less than or equal to ±5%, less than or equal to ±4%, less than or equal to ±3%, less than or equal to ±2%, less than or equal to ±1%, less than or equal to ±0.5%, less than or equal to ±0.1%, or less than or equal to ±0.05%. As another example, a line or a plane can be substantially flat if a peak or depression of the line or plane is no greater than 5 μm, no greater than 1 μm, or no greater than 0.5

As used herein, the singular terms “a,” “an,” and “the” may include plural referents unless the context clearly dictates otherwise. In the description of some arrangements, a component provided “on” or “over” another component can encompass cases where the former component is directly on (e.g., in physical contact with) the latter component, as well as cases where one or more intervening components are located between the former component and the latter component.

While the present disclosure has been described and illustrated with reference to specific arrangements thereof, these descriptions and illustrations are not limiting. It should be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the true spirit and scope of the present disclosure as defined by the appended claims. The illustrations may not necessarily be drawn to scale. There may be distinctions between the artistic renditions in the present disclosure and the actual apparatus due to manufacturing processes and tolerances. There may be other arrangements of the present disclosure which are not specifically illustrated. The specification and the drawings are to be regarded as illustrative rather than restrictive. Modifications may be made to adapt a particular situation, material, composition of matter, method, or process to the objective, spirit and scope of the present disclosure. All such modifications are intended to be within the scope of the claims appended hereto. While the methods disclosed herein have been described with reference to particular operations performed in a particular order, it will be understood that these operations may be combined, subdivided, or reordered to form an equivalent method without departing from the teachings of the present disclosure. Accordingly, unless specifically indicated herein, the order and grouping of the operations are not limitations. 

What is claimed is:
 1. An electronic package structure, comprising: a first electronic component; a second electronic component adjacent to the first electronic component; an interconnection element disposed between the first electronic component and the second electronic component; an insulation layer disposed between the first electronic component and the second electronic component and having a side surface and a top surface connecting to the side surface; and an encapsulant surrounding the interconnection element and at least partially covering the top surface of the insulation layer, wherein the encapsulant has an extended portion in contact with the side surface of the insulation layer.
 2. The electronic package structure of claim 1, wherein the insulation layer has a bottom surface opposite to the top surface of the insulation layer and the extended portion of the encapsulant extends between the top surface of the insulation layer and the bottom surface of the insulation layer.
 3. The electronic package structure of claim 1, wherein the extended portion of the encapsulant is disposed n a gap defined by the side surface of the insulation layer and the interconnection element.
 4. The electronic package structure of claim 3, wherein the encapsulant accommodates the interconnection element.
 5. The electronic package structure of claim 3, wherein the insulation layer comprises a curved corner adjacent to the gap.
 6. The electronic package structure of claim 1, wherein the second electronic component comprises a pad on an upper surface of the second electronic component, the insulation layer has a bottom surface opposite to the top surface of the insulation layer, and the bottom surface is spaced from the pad by a portion of the extended portion of the encapsulant.
 7. The electronic package structure of claim 1, wherein the interconnection element comprises a narrow top portion, a wide middle portion, and a narrow bottom portion.
 8. The electronic package structure of claim 7, wherein the interconnection element comprises a continuous and curved lateral surface.
 9. The electronic package structure of claim 1, wherein the interconnection element comprises a base and a body farther to the second electronic component than the base is, wherein a width of the base is greater than a width of the body.
 10. The electronic package structure of claim 6, wherein the interconnection element comprises a skirt portion contacting the pad.
 11. The electronic package structure of claim 1, wherein the interconnection element comprises a soldering component.
 12. A method for manufacturing an electronic package structure, comprising: providing a first electronic component comprising a first conductive layer and a second electronic component comprising a second conductive layer; pressing the first electronic component to partially interconnect the first conductive layer and the second conductive layer; and applying a condensed energy on the first electronic component to completely interconnect the first conductive layer and the second conductive layer.
 13. The method of claim 12, wherein the step of pressing the first electronic component to partially interconnect is performed via a thermal compression bonding process.
 14. The method of claim 12, wherein the step of applying the condensed energy on the first electronic component is performed via a laser assisted bonding process.
 15. The method of claim 13, wherein the thermal compression bonding process is carried out to form an uneven surface of the first conductive layer facing the first electronic component.
 16. The method of claim 14, wherein the laser assisted bonding process is carried out following the step of pressing the first electronic component to partially interconnect.
 17. An electronic package structure, comprising: an electronic component connected to a carrier through a connection structure; and an encapsulant accommodating the connection structure and comprising an extension between the connection structure and the carrier, wherein the extension is configured to hinder delamination between the encapsulant and an upper surface of the carrier.
 18. The electronic package structure of claim 17, wherein the connection structure is configured to electrically connect the electrical component and the carrier.
 19. The electronic package structure of claim 17, wherein the carrier further comprises an insulation layer disposed adjacent to the upper surface of the carrier, wherein the connection structure defines a gap with the insulation layer and at least a portion of the extension of the encapsulant is disposed in the gap.
 20. The electronic package structure of claim 17, wherein the connection structure comprises a soldering material and the extension of the encapsulant is disposed between the soldering material and the carrier. 